Power and Ease of Use - the winning combination

SolidCAM 2009

SolidCAM+SolidWorks
The complete integrated machining system

Getting started

www.solidcam.com
www.solidcam.com
 SolidCAM + SolidWorks = The complete integrated machining system

SOLIDCAM 4

2.5D MILLING 10

FEATURE RECOGNITION 14

HIGH SPEED SURFACE MACHINING (HSS) 16

3D MILLING 18

HIGH SPEED MACHINING (HSM) 22

MULTI-SIDED MACHINING 26

SIM. 5-AXIS MACHINING 30

TURNING 34

MILL-TURN 38

WIRE CUT 44

SYSTEM REQUIREMENTS 45

TRAINING MATERIALS 46

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 SOLIDCAM
• Don’t go for less. Go for Gold.

SolidCAM is the de-facto standard Gold-Certified integrated CAM-Engine

for SolidWorks. SolidCAM provides seamless, single-window integration and
full associativity to the SolidWorks design model. All machining operations
are defined, calculated and verified, without leaving the SolidWorks
window.

SolidCAM is widely used in the mechanical manufacturing, electronics,

medical, consumer products, machine design, automotive and aerospace
industries, as well as in mold and die and rapid prototyping shops.

Today successful manufacturing companies are using integrated CAD/

CAM systems to get to market faster and reduce costs. With SolidCAM’s
seamless single-window integration in SolidWorks, any size organization
can reap the benefits of the integrated SolidWorks and SolidCAM
solution. SolidWorks + SolidCAM is the Dream-Team for design and
Manufacturing.

SolidCAM supports the complete set of manufacturing technologies.

Following is a brief description of the main SolidCAM modules.

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 SolidCAM + SolidWorks = The complete integrated machining system

• 2.5D Milling

SolidCAM provides both interactive and automated powerful 2.5D milling

operations on SolidWorks models. SolidCAM offers one of the best
pocketing algorithms in the market. Full tool path control and powerful
algorithms ensure that the user can manufacture the way he needs to.
Operations can be easily re-ordered, rotated, mirrored, etc. SolidCAM’s
automatic feature-recognition and machining module automates the
manufacturing of parts with multiple pockets, multiple drills and complex
holes.

All your needs for successful production machining are provided directly
inside SolidWorks with an easy and straightforward interface. SolidCAM
is successfully used in production environments by thousands of
manufacturing companies and job shops.

• High Speed Surface Machining (HSS)

The HSS Module is a High Speed Surface Machining module, for smooth
and powerful machining of localized surface areas in the part, including
undercuts. It provides easy selection of the surfaces to be machined, with
no need to define the boundaries. It supports both standard and shaped
tools.

HSS provides nine different tool path definition strategies that enable the
user to work differently for each area, as needed. The linking moves between
the tool paths can be controlled by the user to avoid holes and slots, without
the need to modify the model surface.

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 Complete gouge control is available for holder, arbor and tool. Adjoining
check surfaces that are to be avoided can be selected. Several retract
strategies are available, under user control.

The HSS module is an important addition to the integrated

SolidWorks+SolidCAM solution and is essential for each manufacturing
facility as an excellent complementary module for the machining of all types
of parts.

• 3D Milling

SolidCAM’s 3D Milling can be used both for prismatic parts and for 3D
models. For prismatic parts SolidCAM analyzes the model and automatically
recognizes pockets and profiles to be machined using Z-constant machining
strategies. For 3D models, SolidCAM offers powerful 3D machining,
including integrated rest material options.

• High Speed Machining (HSM)

SolidCAM HSM module is a very powerful and market-proven advanced

3D Mill and high-speed-machining module for 3D parts, aerospace parts
and molds, tools and dies. The HSM module offers unique machining and
linking strategies for generating advanced 3D Mill and high-speed tool
paths.

SolidCAM’s HSM module smooths the paths of both cutting moves and
retracts wherever possible to maintain a continuous machine tool motion
– an essential requirement for maintaining higher feedrates and eliminating
dwelling.

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 SolidCAM + SolidWorks = The complete integrated machining system

With SolidCAM HSM module retracts to high Z levels are kept to a

minimum. Angled where possible, smoothed by arcs, retracts do not go any
higher than necessary – thus minimizing aircutting and reducing machining
time.

The result of the HSM module is an efficient, smooth, and optimal tool
path. This translates to increased surface quality, less wear on your cutters,
and a longer life for your machine tools.

With demands for ever-shorter lead and production times, lower costs and
improved quality, SolidCAM’s HSM Module is a must in today’s machine
shops.

• 3+2 Axis Multi-Sided Machining

With SolidCAM, programming and machining of multi-sided parts on 4-

and 5-Axis machining centers is efficient and profitable. SolidCAM is an
industry leader in this type of machining. SolidCAM rotates the SolidWorks
model to the user-defined machining planes and automatically calculates all
necessary shifts and tilts for the 3D machining coordinate systems.

SolidCAM enables flexible set-ups and reduces the need for special clamping
jigs. You can define your 2.5D and 3D machining operations on any face
and check them using SolidCAM’s advanced tool path verification. The
output is ready-to-run programs for your 4/5-axis CNC-machine.

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• Simultaneous 5-Axis Machining

Simultaneous 5-axis machining is becoming more and more popular due to

the need for reduced machining times, better surface finish and improved life
span of tools. SolidCAM utilizes all the advantages of Simultaneous 5-Axis
machining and together with collision control and machine simulation,
provides a solid base for your 5-axis solution.

SolidCAM provides intelligent and powerful 5-axis machining strategies,

including swarfing and trimming, for machining of complex geometry parts
including mold cores and cavities, aerospace parts, cutting tools, cylinder
heads, turbine blades and impellers. SolidCAM provides a realistic simulation
of the complete machine tool, enabling collision checking between the tool
and the machine components.

• Turning and Mill-Turn

SolidCAM has a very strong capability in turning, grooving and Mill-Turn.

As in milling, a rest-machining capability is built in all turning operations.
SolidCAM supports all machine turning cycles. SolidCAM provides special
support for the advanced machining technologies of ISCAR’s Turn-Groove
tools.

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 SolidCAM + SolidWorks = The complete integrated machining system

A powerful integrated Mill-Turn capability enables the turning and milling

operations to be programmed in the same environment. Access to the
complete 2.5-5 axis milling is available. SolidCAM provides support for
up to 5-Axis (XYZCB) Turn-Mill CNC machines including back-spindle
operations.

• 2/4 Axis Wire-EDM

SolidCAM Wire EDM handles profiles and tapers with constant and variable
angles, as well as 4-axis contours. SolidCAM’s intelligent algorithms prevent
the falling of material pieces by automatic pocket processing. SolidCAM
provides full user control of stop-points and of wire cutting conditions at
any point of the profile or taper.

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 2.5D MILLING

The 2_5D_Milling_1.prz example illustrates the use of SolidCAM 2.5D Milling to machine
the cover part shown above. The machining is performed on a 3-axis CNC machine in
two setups, one for the top faces and one for bottom faces.

The following SolidCAM operations are created to perform the machining:

• Top face machining (FM_profile_T1)

This Face Milling operation performs the machining of the top face of
the cover. An end mill of Ø20 is used. The machining is performed in
two passes - rough and finish. A machining allowance of 0.2 mm remains
unmachined at the floor, after the rough pass, and is removed during the
finishing pass.

• External faces machining (F_profile1_T2; F_profile2_T2)

These operations perform the profile machining of the external contour of

the cover. An end mill of Ø16 is used. The Clear offset option is used at the
roughing stage to perform the machining in a number of equidistant offsets
from the machining geometry. The machining allowance is left unmachined
during the roughing operation and removed at the finishing stage.

• Bolt seats machining (F_profile3_T3)

This operation is used to remove the material at the bolt seat areas. An end
mill of Ø8 is used for the operation.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Bottom face machining (FM_profile4_T1)

This Face Milling operation performs the machining of the bottom face
of the cover. This operation uses the second Coordinate system; it means
that the second setup has to be performed at the CNC machine before
the machining. The used tool and the machining strategy are similar to the
FM_profile_T1 operation.

• Internal faces roughing (P_profile5_T2; P_profile6_T2)

These Pocket operations perform the rough machining of the internal faces
of the cover. An end mill of Ø16 is used. The rough machining is divided
into two operations to perform the machining with the optimal tool path
The machining allowance is left unmachined for further finish operations.

• Internal faces rest machining (P_profile6_T4)

This operation uses the rest material machining technique in order to

machine the areas left inaccessible for the large tools used in the previous
operations. An end mill of smaller diameter (Ø8) is used.

• Internal faces finishing (F_profile5_T4; F_profile7_T4)

These operations perform the wall finishing of the internal pocket area of
the cover part. An end mill of Ø6 is used.

• Floor faces finishing (F_profile7_T3; P_profile6_T4_1)

These operations perform the floor finishing of the internal pocket area of
the cover part. End mill tools of Ø6 and Ø8 are used.

• Slot machining (S_slot_T5)

This Slot Milling operation performs the machining of the groove at the
bottom face of the cover. An end mill of Ø1.5 is used.

• Holes machining D_drill_T6; D_drill_T7

These Drill operations perform the сenter drilling and drilling of the four
holes of Ø5 located at the bottom face of the cover.

• Threaded holes machining (D_drill1_T6; D_drill1_T8; D_drill1_T9)

These Drill operations perform the сenter drilling, drilling and threading of
the M2 holes located at the pads.

For more information see Exercise #3 of the SolidCAM 2.5D Milling Training Course.
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 2.5D MILLING

The 2_5D_Milling_2.prz example illustrates the use of SolidCAM 2.5D Milling to machine
the part shown above. The machining is performed on a 3-axis CNC machine in two
setups, using two SolidCAM Coordinate systems.

The following SolidCAM operations are created to perform the machining:

• Upper faces machining (F_profile_T1; F_profile1_T1)

These Profile operations remove the bulk of material performing the rough
and the finish machining of upper faces. An end mill of Ø16 is used. The
Clear offset option is used at the roughing stage to perform the machining
in a number of equidistant offsets from the machining geometry.

• Step faces machining (F_profile2_T1)

This operation performs the rough and finish machining of the step faces
using the Profile operation. An end mill of Ø16 is used.

• External contour machining (F_profile3_T1)

This operation performs the rough and finish machining of the external
model faces. An end mill of Ø16 is used.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Connector pocket machining (P_profile4_T1; P_profile5_T2;

F_profile13_T2; F_profile6_T2; P_profile4_T3

A number of Profile and Pocket operations are used to perform the rough
and finish machining of the connector pocket. End mill tools of Ø10; Ø3
and Ø4 are used. The Rest material strategy is used in the last operation to
complete the machining of the connector faces.

• Machine screw head areas (F_profile7_T3)

This operation performs the rough and finish machining of the screw head
areas. An end mill tool of Ø4 is used.

• Top and Bottom face machining (FM_profile1_T1;

FM_facemill1_T1)

Two Face Milling operation enable you generate the tool path for roughing
and finishing of the top and bottom faces. Note that the second operation
is used with the second Coordinate System, it means that the second setup
has to be performed at the CNC machine before the machining.

• Internal faces roughing (P_profile11_T1; P_profile12_T1)

These Pocket operations perform the roughing of the complex pocket

formed by the internal faces of the part. An end mill tool of Ø10 is used.

• Internal faces roughing (F_profile11_T4; F_profile12_T4;

P_profile8_T4; F_profile9_T4)

These Pocket and Profile operations perform the finish machining of the
wall and floor faces if the complex pocket roughed at the previous stage. An
end mill tool of Ø4 is used.

• Holes machining (D_drill_T5; D_drill1_T5; D_drill2_T5; D_drill_T6;

D_drill1_T7; D_drill2_T8;

These Drill operations perform center drilling and drilling of holes located
on the cover part faces.

For more information see Exercise #8 of the SolidCAM 2.5D Milling Training Course.

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 FEATURE RECOGNITION

The drill_pocket_recognition.prz example illustrates the use of SolidCAM Automatic

Feature Recognition to machine the mold base part shown above. The machining is
performed on a 3-axis CNC machine.

The following SolidCAM operations are created to perform the machining:

• Top face machining (FM_facemill_T1)

This Face Milling operation performs the machining of the top face of the
cover. A face mill of Ø40 is used.

• Pockets machining (PR_selected_faces_T2)

This Pocket Recognition operation automatically recognizes all the pocket

areas in the model and performs their machining. An end mill of Ø20
is used. The Open Pocket machining is used to perform the approach
movement from an automatically calculated point outside of the material.
The tool descends to the necessary depth outside of the material and then
moves horizontally into the material. A special machining strategy is applied
to the through pockets; they are deepened in order to completely machine
the pocket.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Center Drilling (DR_drill_r_T3)

This Drill Recognition operation automatically recognizes all the hole

features available for the machining with the current Coordinate System and
performs the center drilling of all the holes in the mold base. An spot drill
of Ø10 is used. The drilling depth is customized for each group of holes.

• Drilling (DR_drill_r1_T4; DR_drill_r2_T5; DR_drill_r3_T4;

DR_drill_r4_T6, DR_drill_r5_T7, DR_drill_r6_T8)

These Drill Recognition operations perform the machining of all the hole
features automatically recognized in the mold base. SolidCAM automatically
recognized the Upper Level and Drill depth from the model. The through
holes are extended in order to completely machine the holes.

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 HIGH SPEED SURFACE
MACHINING (HSS)

The hss.prz example illustrates the use of several SolidCAM High Speed Surface
Machining (HSS) strategies to machine the base part shown above.

The following SolidCAM operations are created to perform the machining:

• Engraving (HSS_Engraving_selected_faces_T1,
HSS_Engraving_selected_faces1_T1,
HSS_Engraving_selected_faces2_T1,
HSS_Engraving_selected_faces3_T1)

These operations utilize the HSS Engraving strategy to perform the machining
of four fillet areas. A ball nose mill of Ø10 is used. The Depth Cut option is
used to machine the whole the depth in several cutting passes.

• Morphing machining (HSS_MORPH_CURVES_selected_faces4_T1,

HSS_MORPH_CURVES_selected_faces6_T1)

This operation performs the machining of two internal fillet areas using
the Morph between two curves strategy. This strategy is utilized to generate
the tool path evenly distributed between the fillet boundaries. The gouge
checking strategy is used to avoid possible gouges between the tool and the
faces of the machining area. A ball nose mill of Ø10 is used.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Parallel to curve machining (HSS_ParToCurve_selected_faces8_T1)

This operation performs the machining of the part bottom face. With
this strategy, SolidCAM enables you to perform the machining of faces
with cutting passes parallel to the selected curve. In this case, SolidCAM
generates a pocket-style tool path enclosed within the boundaries of the
selected face. An end mill of Ø8 is used.

• Morphing between two curves (HSS_MORPH_CURVES_selected_

faces11_T2)

This operation performs the machining of the external fillet and an inclined
face adjacent to the fillet. The Morphing between two curves strategy
is utilized to generate the tool path evenly distributed between the fillet
boundaries. The tool path is generated using the Scallop of 0.004 mm in
order to obtain excellent surface quality. The gouge checking strategy is used
to avoid possible gouges between the tool and the faces of the machining
area. A ball nose mill of Ø6 is used.

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 3D MILLING

The 3D_Milling_1.prz example illustrates the use of SolidCAM 3D Milling for the
machining of the mold core shown above.

The following SolidCAM operations are created to perform the machining:

• Roughing (3DR_target_T1)

This operation removes the bulk of material using the Contour roughing
strategy. An end mill of Ø20 is used. The machining is performed at the
constant-Z levels defined, using the Step down value of 3 mm. A machining
allowance of 1 mm remain unmachined for further finish operations.

• Rest material machining (3DR_target_T2)

This operation performs the rest material machining of the areas that
were inaccessible to the tool in the previous operation. An end mill tool of
smaller diameter (Ø16) is used. The Contour roughing strategy is utilized
in combination with the Rest material mode of the Working area definition
in order to obtain optimal and effective tool path removing the cusps left
after the previous operation. A machining allowance of 0.5 mm remains
unmachined for further finish operations.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Steep areas finishing (3DF_CZ_target_T3)

This operation performs the Constant-Z finishing of the steep areas of the
core. With this strategy, SolidCAM machines a number of planar sections,
parallel to the XY plane, using profile machining. A ball nose mill of Ø10 is
used. The machining is performed for the steep areas, with inclination angle
from 30° to 90°

• Shallow areas finishing (3DF_CS_target_T3)

This operation performs the Constant Stepover finishing of the shallow areas
of the core. With this 3D Milling strategy SolidCAM generates a number of
tool paths, at specified constant offset (Step over) from each other, measured
along the surface. The machining is performed for the shallow areas, with
inclination angle from 0° to 32°. A ball nose mill of Ø10 is used.

• Parting surface finishing (3DF_Lin_target_T3)

This operation performs the Linear finishing of the parting surface of the
core. In linear finishing, SolidCAM generates a line pattern on a 2D plane
above the model and then projects it on the 3D Model. The Step over
value determines the constant distance between adjacent lines of the linear
pattern, created on the 2D plane before being projected. A ball nose mill of
Ø10 is used. The defined Drive/Check surfaces enable you to perform the
machining of the parting surfaces only, avoiding unnecessary contact with
the already machined faces.

For more information see Exercise #1 and Exercise #10 of the SolidCAM 3D Milling Training
Course.

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 3D MILLING

The 3D_Milling_2.prz example illustrates the use of SolidCAM 3D Milling for prismatic
part machining.

The following SolidCAM operations are created to perform the machining:

• Roughing (3DR_target_T1)

These operations remove the bulk of material using the Contour roughing
strategy. An end mill of Ø10 is used. The Open Pocket machining is used
to perform the approach movement from an automatically calculated point
outside of the material. The tool descends to the necessary depth outside
of the material and then moves horizontally into the material. A machining
allowance of 0.2 mm remain unmachined on floor and wall faces for further
finish operations.

• Rest material machining (3DR_target_T2; 3DR_target_T3)

At this stage the rest material machining is performed for the corner areas,
that were inaccessible by the tool in the previous operation. The machining
is performed in two operations using end mills of Ø8 and Ø5, in order
to minimize the tool load. The Contour roughing strategy is utilized in
combination with the Cut only in Rest material option in order to obtain
optimal tool path A machining allowance of 0.2 mm remain unmachined
on the floor and wall faces for further finish operations.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Vertical walls finishing (3DF_CZ_target_T4)

This operation performs the Constant-Z Wall finishing of the vertical walls
areas of the part. With this strategy, SolidCAM generates a number of
profile passes along the Z-axis, with a constant Step down. An end mill of
Ø4 is used.

• Horizontal floor finishing (3DF_CZ_target_T4_1)

This operation performs the Constant-Z Floor finishing of the horizontal

floor areas of the part. With this strategy, SolidCAM generates a number
of pocket passes on the horizontal faces, parallel to the XY-plane of the
current Coordinate System. An end mill of Ø4 is used.

For more information see Exercise #18 of the SolidCAM 3D Milling Training Course.

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 HIGH SPEED MACHINING (HSM)

The hsm_1.prz example illustrates the use of several SolidCAM High Speed Machining
(HSM) strategies to machine the mold cavity shown above.

The following SolidCAM operations are created to perform the machining:

• Rough machining (HSM_R_Cont_target_T1A)

This operation performs contour roughing of the cavity. An end mill of

Ø20 is used with a Step down of 3 mm. A machining allowance of 0.5 mm
remain unmachined for further semi-finish and finish operations.

• Rest roughing (HSM_RestR_target_T2A)

This operation performs rest roughing of the cavity. A bull nosed tool of
Ø12 and corner radius of 2 mm is used with a Step down of 1.5 mm to
remove the steps left after the roughing. The same machining allowance as
in roughing operation is used.

• Steep faces semi-finishing (HSM_CZ_target_T3A)

This operation performs Constant Z semi-finishing of the steep faces (from

40° to 90°). A ball nosed tool of Ø10 is used for the operation. A machining
allowance of 0.25 mm remain unmachined for further finish operations.
The Apply fillet surfaces option is used to add virtual fillets that will smooth
the tool path at the corners.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Shallow faces semi-finishing (HSM_Lin_target_T3A)

This operation performs Linear semi-finishing of the shallow faces (from

0° to 42°). A ball nosed tool of Ø10 is used for the operation. A machining
allowance of 0.25 mm remain unmachined for further finish operations.
The Apply fillet surfaces option is used.

• Corners rest machining (HSM_RM_target_T4A)

This operation uses the Rest Machining strategy for semi-finishing of the
mold cavity corners. The semi-finishing of the model corners enables you
to avoid tool overload in the corner areas during further finishing. A ball
nosed tool of Ø6 is used for the operation. A virtual reference tool of
Ø12 is used to determine the model corners where the rest machining is
performed. A machining allowance of 0.25 mm remain unmachined for
further finish operations.

• Steep faces finishing (HSM_CZ_target_T5A)

This operation performs Constant Z finishing of the steep faces (from 40°
to 90°). A ball nosed tool of Ø8 is used for the operation. The Apply fillet
surfaces option is used.

• Shallow faces finishing (HSM_Lin_target_T5A)

This operation performs Linear finishing of the shallow faces (from 0° to

42°). A ball nosed tool of Ø8 is used for the operation. The Apply fillet
surfaces option is used.

• Corners rest machining (HSM_RM_target_T6A)

This operation uses the Rest Machining strategy for finishing of the model
corners. A ball nosed tool of Ø4 is used for the operation. A virtual
reference tool of Ø10 is used to determine the model corners where the
rest machining is performed.

• Chamfering (HSM_Bound_target_T7A)

This operation uses the Boundary Machining strategy for the

chamfering of upper model edges. A taper tool is used for the operation.
The chamfer is defined by the external offset of the drive boundary and by
the Axial thickness parameter.

For more information see Exercise #16 of the SolidCAM HSM User Guide.

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 HIGH SPEED MACHINING (HSM)

The hsm_2.prz example illustrates the use of several SolidCAM HSM strategies to
machine the electronic box shown above.

The following SolidCAM operations are created to perform the machining:

• Rough machining (HSM_R_Cont_target1_T1A)

This operation performs the contour roughing of the part. An end mill
of Ø30 is used with a Step down of 10 mm to perform the roughing. A
machining allowance of 0.5 mm remain unmachined for further semi-finish
and finish operations.

• Rest roughing (HSM_RestR_target1_T2A)

This operation performs the rest roughing of the part. A bull nosed tool
of Ø16 and corner radius of 1 mm is used with a Step down of 5 mm to
remove the steps left after the roughing. The same machining allowance as
in the roughing operation is used.

• Upper faces machining (HSM_CZ_target_T3A)

This operation performs Constant Z finishing of the upper vertical model

faces upto a certain depth. A bull nosed tool of Ø12 and corner radius of
0.5 mm is used.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Bottom faces machining (HSM_CZ_target_T3A_1)

This operation performs Constant Z finishing of the bottom vertical model

faces. A bull nosed tool of Ø12 and corner radius of 0.5 mm is used.

• Flat faces machining (HSM_CZF_target1_T3A)

This operation performs Horizontal Machining of the flat faces. A bull

nosed tool of Ø12 and corner radius of 0.5 mm is used.

• Inclined faces machining (HSM_CZ_target1_T4A)

This operation performs Constant Z Machining of the inclined faces. A

taper mill of 12° angle is used to perform the machining of the inclined face
with large stepdown (10 mm). Using such a tool enables you to increase the
productivity of the operation.

For more information see Exercise #14 of the SolidCAM HSM User Guide.

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 MULTI-SIDED MACHINING

The multi_sided_machining_1.prz example illustrates the use of SolidCAM Multi-sided

machining to machine the manifold plate shown above, using a 5-axis CNC Machine.
The initial stock for this example comes from casting.

The following SolidCAM operations are created to perform the machining:

• Top face machining (FM_profile_T1)

This Face Milling operation performs the machining of the top face of the
cover. An end mill of Ø16 is used. The machining is performed in two passes
- rough and finish. A machining allowance of 0.2 mm remain unmachined
at the floor after the rough pass and removed during the finishing pass.
Position #1 of the Machine Coordinate system is used for the operation.

• Front hole machining (D_drill_T2; D_drill_T3; D_drill_T4;

F_profile1_T1)

These operations are used for the front hole machining using Position #2
of the Machine Coordinate system. The Drill operations perform center-
drilling and two steps drilling of the hole. The Profile operation is used for
the machining of the connector faces around the hole.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Left hole machining (D_drill1_T2; D_drill1_T3; D_drill1_T4;

F_profile2_T1)

These operations are used for the left hole machining using Position #3
of the Machine Coordinate system. The sequence of the Drill and Profile
operations is similar to the sequence used for the front hole machining.

• Back hole machining (D_drill2_T2; D_drill2_T3; D_drill2_T4;

F_profile3_T1)

These operations are used for the left hole machining using Position #4
of the Machine Coordinate system. The sequence of the Drill and Profile
operations is similar to the sequence used for the front hole machining.

• Right hole machining (D_drill3_T2; D_drill3_T3; D_drill3_T4;

F_profile4_T1)

These operations are used for the left hole machining using Position #5
of the Machine Coordinate system. The sequence of the Drill and Profile
operations is similar to the sequence used for the front hole machining.

• Top holes machining (P_profile5_T5; D_drill4_T2; D_drill4_T6;

D_drill4_T7; D_drill5_T2; D_drill5_T8; F_profile6_T5)

These operations are used for the machining of the holes located on the top
faces of the model. Position #1 of the Machine Coordinate system is used
for all the operations.

For more information see Exercise #13 of the SolidCAM 2.5D Milling Training Course.

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 MULTI-SIDED MACHINING

The multi_sided_machining_1.prz example illustrates the use of SolidCAM Multi-sided

machining to complete the machining of the clamp part shown above, using a 5-axis
CNC Machine.

The following SolidCAM operations are created to perform the machining:

• Top face machining (FM_profile1_T1)

This Face Milling operation machines the top inclined face of the clamp.
Machine Coordinate system #1 (Position #2) is used for the operation.

• Back face machining (FM_profile2_T1)

This Face Milling operation machines the back inclined face of the clamp.
Machine Coordinate system #1 (Position #3) is used for the operation.

• Front face machining (FM_profile3_T1)

This Face Milling operation machines the front inclined face of the clamp.
Machine Coordinate system #1 (Position #4) is used for the operation.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Openings machining (F_profile4_T1)

This Profile operation machines two openings, located on the front inclined
face of the clamp. Machine Coordinate system #1 (Position #4) is used for
the operation.

• Slot machining (P_profile5_T2; P_profile6_T2)

These Pocket operations machines the slot faces located on the top inclined
face of the clamp, using the Contour strategy. Machine Coordinate system
#1 (Position #2) is used for the operation.

• Hole machining (P_profile7_T2; D_drill_T3 D_drill_T4)

These operations machine the inclined counterbore hole, located on the top
inclined face of the clamp. Machine Coordinate system #1 (Position #5) is
used for the operation.

• Bottom face machining (FM_profile8_T1)

This Face Milling operation machines the bottom inclined face of the clamp.
Machine Coordinate system #2 (Position #1) is used for the operation.

For more information see Exercise #15 of the SolidCAM 2.5D Milling Training Course.

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 SIM. 5-AXIS MACHINING

The sim_5_axis_1.prz example illustrates the use of the SolidCAM Sim. 5 axis module for
turbine blade machining.

The following Sim. 5 axis operations are used to perform the semi-finish and finish
machining of the turbine blade:

• Blade Semi-finishing
(5X_selected_faces_T1A_1; 5X_selected_faces_T2A_3)

The first operation provides the semi-finish of the turbine blade, using a
bull nosed tool of Ø16 with a corner radius of 4 mm. A combination of
the Parallel Cuts strategy and Change parallel cuts to spiral option is used to
perform the spiral machining of the blade.

The tool tilting is defined using the Tilted relative to cutting direction option,
with lag angle of 20°. The tool contact point is defined at the front tool face.
This combination of parameters enables you to perform the machining by
the toroidal surface of the tool.

Gouge checking is performed to avoid the possible collisions of the tool

with the planar surface of the blade base. The remaining material will be
machined at a later stage, using a special tilting strategy.

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 SolidCAM + SolidWorks = The complete integrated machining system

The second Sim. 5-axis operation provides semi-finishing of the blade

area, close to the blade base. This area was not machined in the previous
operation because of the gouge protection. A bull nosed tool of Ø8, with
a corner radius of 2 mm, is used for the operation. Similar to the previous
operation, a combination of the Parallel Cuts strategy and Change parallel
cuts to spiral option is used to perform the spiral machining of the blade.

The tool tilting is defined using the Tilted relative to cutting direction option,
with a lag angle of 20°. In addition to the lag angle, a side tilting angle of 10°
is defined to avoid the gouging of the planar face of the blade base.

• Blade finishing (5X_selected_faces_T3A)

This operation performs the finishing of the blade. A bull nosed tool of
Ø8, with a corner radius of 2.5 mm, is used for the operation.

The tool tilting is defined using the Tilted relative to cutting direction option
with a lag angle of 20°. In addition to the lag angle, a side tilting angle of 10°
is defined to avoid the gouging of the planar face of the blade base.

For more information see Exercise #2 of the SolidCAM Sim. 5-axis User Guide.

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 SIM. 5-AXIS MACHINING

The sim_5_axis_2.prz example illustrates the use of the Sim. 5 axis operation for an
aerospace part machining.

A number of Sim. 5 axis operations are defined in order to perform the finish machining
of the inclined faces of the aerospace frame and their adjacent fillets. The inclined faces
are forming an undercut area that cannot be machined using 3 axis milling; we have to
use 5 axis milling, with the appropriate tilting strategy, to machine the inclined faces.

• Inclined walls finishing

(5X_selected_faces1_T1A; 5X_selected_faces2_T1A;
5X_selected_faces3_T1A)

These operations perform the finish machining of the inclined walls.

A ball nosed tool of Ø4 is used for the operation.

The Parallel Cuts strategy is used to generate a number of cuts parallel to the
XY plane of the coordinate system.

The tool tilting is defined using the Tilted relative to cutting direction option
with a lag angle of 90°. These parameters enable you to perform the
machining with the side face of the tool.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Fillet machining
(5X_selected_faces4_T1A; 5X_selected_faces5_T1A;
5X_selected_faces6_T1A)

These operations perform the finish machining of the fillets adjacent to

the walls.

A ball nosed tool of Ø4 is used for the operation.

The Project curves strategy is used to generate a single pencil milling pass,
machining the fillets.

The Tilted through curves tilting strategy is used to perform a smooth

transition between different tool axis orientations.

For more information see Exercise #3 of the SolidCAM Sim. 5-axis User Guide.

33
 TURNING

The turning_1.prz example illustrates the use of the SolidCAM Turning for the machining
of the part shown above.

The following Turning operations are used to perform the machining of the part:

• External Roughing (TR_profile_T1A)

This operation is used to generate the tool path for the external faces
roughing. An External roughing tool is used for the operation. The Long
Process type is chosen for the operation to perform the machining in
longitudinal direction. The Rough Work type is chosen for the operation;
with this Work type the rough machining is performed in a number of
equidistant passes.

• Facial Turning (TR_profile1_T1A)

This operation is used to generate the tool path for the front face machining.
An External roughing tool is used for the operation. The Face Process type is
chosen for the operation to perform the machining in facial direction. The
Rough work type is chosen for the operation; with this work type the rough
machining is performed in a number of equidistant passes.

• Drilling (DRILL__T2A)

This Drill operation is used to perform the rough machining of the hole. A
U-Drill tool of Ø28 is used for the operation.

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 SolidCAM + SolidWorks = The complete integrated machining system

• External Finishing (TR_profile_T3A)

This Turning operation is used to perform the external faces finishing.

The Profile Work type is chosen to generate the finishing pass. An External
roughing tool is used for the operation.

• Internal Turning (TR_profile2_T4A)

This Turning operation is used to perform the internal faces finishing.

The Profile Work type is chosen to generate the finishing pass. An Internal
roughing tool is used for the operation.

• External Grooving (GR_profile3_T5A)

This Grooving operation is used to perform rough and finish machining

of the external groove faces. An External grooving tool is used for the
operation.

• Internal Grooving (GR_profile4_T6A)

This Grooving operation is used to perform rough and finish machining

of the internal groove faces. An Internal grooving tool is used for the
operation.

• External Threading (TH_profile5_T7A)

This Threading operation is used to perform the machining of the external

thread with the minimal diameter of 56 mm and pitch of 1.5 mm. An
External threading tool is used for the operation.

• Internal Threading (TH_profile6_T8A)

This Threading operation is used to perform the machining of the internal

thread with the maximal diameter of 33.5 mm and pitch of 1.5 mm. An
Internal threading tool is used for the operation.

• Parting (GR_profile7_T9A)

This Grooving operation is used to perform the parting (cut-off) of the

machined part from the stock bar. The Cut Work type is used for the
operation. An External grooving tool is used for the operation.

For more information see Exercise #1—#11 of the SolidCAM Turning Training Course.

35
 TURNING

The turning_2.prz example illustrates SolidCAM functionality for Rest Material machining,
during longitudinal and facial rough/finish turning operations, performed on the wheel
part shown above.

The following Turning operations are used to perform the machining of the part:

• External Roughing (TR_profile_T1A)

This operation is used to generate the tool path for the external faces
roughing. An External roughing tool is used for the operation. The Long
Process type is chosen for the operation to perform the machining in the
longitudinal direction. The Rough Work type is chosen for the operation;
with this Work type the rough machining is performed in a number of
equidistant passes.

• External Rest Material Roughing (TR_profile_T2A)

This operation utilizes the Rest Material option to perform the machining
of the areas left unmachined after the previous operation. These areas were
unmachined because of the orientation and geometry of the tool used in
the previous operation. In this operation a tool with opposite orientation is
used to machine the part, moving in the positive Z-direction.

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 SolidCAM + SolidWorks = The complete integrated machining system

• External Finishing (TR_profile1_T3A)

This Turning operation is used to perform the external faces finishing.

The Profile Work type is chosen to generate the finishing pass. An External
Contour tool is used for the operation to avoid leaving unmachined areas
during the external finish.

• Facial Roughing (TR_profile2_T4A)

This operation is used to generate the tool path for the front face roughing.
An External roughing tool is used for the operation. The Face Process type is
chosen for the operation to perform the machining in facial direction. The
Rough work type is chosen for the operation; with this work type the rough
machining is performed in a number of equidistant passes.

• External Rest Material Roughing (TR_profile2_T5A)

This operation utilizes the Rest Material option to perform the machining
of the areas left unmachined after the previous operation. These areas were
unmachined because of the orientation and geometry of the tool used in
the previous operation. In this operation the tool with opposite orientation
is used to machine the part, moving in the positive X-direction.

• External Facial Finishing (TR_profile2_T4A_1)

This Turning operation is used to perform the front face finishing. The
Profile Work type is chosen to generate the finishing pass. An External
roughing tool is used for the operation.

• External Rest Material Finishing (TR_profile2_T5A_1)

This operation utilizes the Rest Material option to perform the machining
of the areas left unmachined after the previous finishing operation. These
areas were unmachined because of the orientation and geometry of the
tool used in the previous operation. In this operation the tool with opposite
orientation is used to machine the part, moving in the positive X-direction.
The Profile Work type is chosen to generate the finishing pass.

• Hole machining (DRILL__T6A)

This Drill operation is used to perform the machining of the hole. A

U-Drill tool of Ø40 is used for the operation.

For more information see Exercise #16 of the SolidCAM Turning Training Course.

37
 MILL-TURN

The mill_turn_1.prz example illustrates the use of the SolidCAM Mill-Turn module for
the machining of the optical part shown above, on a 4-axis Mill-Turn CNC-Machine.

The following Turning and Milling operations are used to perform the machining of the
part:

• Turning
(TR_profile1_T1; TR_profile1_T1_1; DRILL__T7; TR_profile10_T8)

These turning operations are used to generate the tool path for the rough
and finish machining of the external and internal cylindrical faces.

• Facial Milling (F_profile2_T2; D_drill3_T6; D_drill4_T6)

These operations perform the machining of the screw slot and four holes
using SolidCAM capabilities for facial milling. Position #1 of Coordinate
System #1 is used to perform the facial machining.

• Machining of the side faces (P_profile3_T3)

This Pocket operation is used to perform the machining of the side faces of
the model. The Contour strategy is used in combination with a negative Wall
offset value in order to generate an overlapping tool path that completely
machines the faces.

Position #3 of Coordinate System #1 is used for the operation. The

Transform option is used to create a circular pattern of operations around
the revolution axis.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Drilling on the side face (D_drill_T4)

This Drill operation is used to perform the machining of two holes located
on the side face of the model. CoordSys Position #3 is used for the
operation.

• Slot machining (F_profile5_T2)

This Profile operation is used to perform the machining of the slot using
indexial 4-axis milling.

Position #4 of Coordinate System #1 is used for the operation.

An end mill of Ø2.5 is used for the operation.

• Radial holes machining

(D_drill1_T5; P_profile6_T2; D_drill2_T5; P_profile7_T2)

These Drill and Pocket operations are used to perform the machining of
three counterbore holes located on the cylindrical face.

Position #5 and Position #6 of Coordinate System #1 are used for the

operations.

• Pocket machining (P_profile9_T2)

This Pocket operation is used to perform the simultaneous 4-axis machining

of the pocket, wrapped on the external face of the part. Position #2 of
Coordinate System #1 is used to perform the pocket machining. An end
mill of Ø2.5 is used for the operation.

The Wrap option, chosen during the machining geometry definition, enables
you to define the wrapped geometry of the pocket directly on the solid
model.

The Contour strategy is chosen for the pocket machining.

39
 MILL-TURN

The mill_turn_2.prz example illustrates the use of the SolidCAM Mill-Turn module for
the machining of the console part shown above on a 5-axis Mill-Turn CNC-Machine.

The following Turning and Milling operations are used to perform the machining of the
part:

• Turning (TR_profile_T1)

This turning operation is used to generate the tool path for the rough and
finish machining of the external cylindrical faces.

• Indexial milling (F_profile6_T2)

This Profile operation is used to perform the machining of the cube sides
using the SolidCAM indexial milling capabilities. Position #2 of Coordinate
System #2 is used for the operation. The Transform option is used to create
a circular pattern of operations around the revolution axis in order to
machine all the cube faces.

An end mill of Ø16 is used for the operation.

• Horizontal faces machining (F_profile1_T2)

This Profile operation is used to perform the indexial milling of the

horizontal faces at the front part of the console. Position #4 of Coordinate
System #1 is used for the operation.

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 SolidCAM + SolidWorks = The complete integrated machining system

The Transform option is used to create a circular pattern of operations

around the revolution axis in order to machine both sides of the console’s
front part.

• Inclined faces machining (F_profile3_T2; F_profile4_T2)

These Profile operations are used to perform the machining of the inclined
faces using the B-axis. CoordSys positions #5 and #6 are used for these
operation.

An end mill of Ø16 is used for the operations.

• Cylindrical face machining (F_profile2_T2A)

This Profile operation is used to perform the machining of the cylindrical

face at the front part of the console. Position #4 of Coordinate System #1
is used for the operation.

An end mill of Ø16 is used for the operations.

• Pocket machining (P_profile9_T3)

This Pocket operation is used to perform the machining of the pocket

located on the inclined faces, using the B-axis. Position #5 of Coordinate
System #1 is used for the operation.

An end mill of Ø6 is used for the operation.

• Inclined faces machining (F_profile7_T2; F_profile8_T2)

These Profile operations are used to perform the machining of the inclined
faces on the cube, using the B-axis. CoordSys positions #7 and #8 are used
for the operation.

An end mill of Ø16 is used for the operation.

• Hole machining (D_drill_T4; D_drill1_T5; D_drill2_T6; D_drill3_T6)

These Drill operations are used to perform the machining of the inclined
faces on the cube, using the B-axis. CoordSys positions #4, #6, #7 and #8
are used for the operations.

41
 MILL-TURN - 2 SPINDLES

The back_spindle.prz example illustrates the use of the SolidCAM Back Spindle
functionality for the machining of the connector part shown above, on a 5-axis Mill-
Turn CNC-Machine.

The following Turning and Milling operations are used to perform the machining of the
part:

• Turning and front side milling (TR_profile_T1A; TR_profile_T1A_1;

DRILL__T2A; F_profile1_T3A; TR_profile2_T4A)

These operations are used to perform turning and facial milling of the front
faces of the connector. Position #1 of Coordinate System #1 is used for
the operation. The back spindle is not used in these operations; only the
main spindle is used.

• Indexial machining of the middle part

(F_profile6_T5A; D_drill2_T6A; D_drill2_T7A; F_profile7_T8A)

These Profile and Drill operations are used to perform the machining of
the pads and holes located around the cylindrical surface, in the middle
part of the connector. Position #5 of Coordinate System #1 is used for
the operation. The Back Spindle Connect operation is defined before these
operations, enabling the combined use of both spindles (main and back) in
these operations.

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 SolidCAM + SolidWorks = The complete integrated machining system

• Indexial machining of the back part

(P_profile8_T9A; D_drill3_T10A)

These Profile and Drill operations are used to perform the machining of
the pads and holes located around the conical surface, in the middle part
of the connector. Position #6 of Coordinate System #1 is used for the
operation. The Back Spindle MoveBack operation is defined before these
operations, causing the retract of the back spindle, so that these operations
are performed with the main spindle only.

• Turning and back side milling

(TR_profile9_T1B; F_profile10_T11A; DRILL_T12A; TR_profile11_
T13A; F_profile12_T14A; D_drill4_T15A; D_drill4_T16A)

These operations are used to perform turning and facial milling of the
back faces of the connector. Position #1 of Coordinate System #1 is used
for turnings operation. Position #4 of Coordinate System #1 is used for
milling operations. The Back Spindle Transfer operation is defined before
these operations, causing the transfer of the part from the main spindle to
the back spindle. The machining is performed on the part clamped in the
back spindle.

Refer to the SolidCAM Turning User Guide for more information about the Back spindle
functionality.

43
 WIRE CUT

The wire_cut.prz example illustrates the use of the SolidCAM Wire Cut module for the
conical gear machining.

The following Wire Cut operations are used to perform the machining of the part:

• Central cut machining (F_profile)

This Profile operation is used to machine the central through cut. The
Later option is used for the Auto Stop technology, generating a postponed
separate sub-operation preventing the material dropping.

• Gear face machining (X_four_axis)

The 4-axis operation is used to machine the conical gear shape. The insertion
point of the wire is chosen outside the cylindrical stock, simplifying the
approach of the wire to the machining contour.

Refer to the Wire Cut User Guide for more information about the Wire Cut module.

44
 SYSTEM REQUIREMENTS

• Microsoft® Windows Vista x32/x64 Business and Ultimate editions with

Service Pack 1, Microsoft® Windows XP Professional with Service Pack 2
(recommended), Microsoft® Windows XP Professional x64 Edition

• Intel® Pentium™, Intel® Xeon™, Intel® Core™, Intel® Core™2 Duo, Intel®
Core™2 Quad, AMD® Athlon™, AMD Athlon™ X2 Dual-Core - class processor
(emphasized processors are recommended)

• 2 GB RAM or more (4 GB or more for x64 operating system is recommended

for large CAM-Parts machining)

• A OpenGL workstation graphics card (512 MB RAM recommended) and

latest driver

• Mouse or other pointing device

• CD drive

• Internet Explorer version 6 if you are using the SolidCAM online help

• For viewing SolidCAM User Guides and Training Courses, Adobe Acrobat
version 9 or higher is recommended.

45
 TRAINING MATERIALS

The following training courses are suitable both for SolidCAM frontal training and for
self study.

• SolidCAM Milling Training Course: 2.5D Milling

• SolidCAM Milling Training Course: 3D Milling

• SolidCAM Turning Training Course

• SolidCAM Turn-Mill Training Course

• SolidCAM Advanced Training Course

These documents are available in the following format: PDF for on-line use +
Examples

The following user guides for SolidCAM are available.

• SolidCAM Milling User Guide

• SolidCAM HSM User Guide

• SolidCAM Sim. 5-axis User Guide

• SolidCAM Turning User Guide

• SolidCAM Wire Cut User Guide

The PDF versions of user guides are available for download from the Download area of
SolidCAM Web site: www.solidcam.com.

On-line help, based on these user guides, is available within SolidCAM.

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 SolidCAM + SolidWorks = The complete integrated machining system

47
www.solidcam.com

©2009 SolidCAM LTD. All rights reserved.